Sarka
sheet material forming apparatus

ABSTRACT

A PAIR OF ROTARY CYLINDERS DEFINE A MATERIAL FORMING NIP. THE ROTARY CYLINDERS HAVE COMPLEMENTARY DIE PLATES MOUNTED THEREON. THE DIE PLATES HAVE PROJECTING MEANS THEREON WHICH COOPERATE TO SIMULTANEOUSLY CUT AND CREASE SHEET MATERIAL AS IT IS ADVANCED THEREBETWEEN. MEANS IS PROVIDED FOR CONVEYING AND INTRODUCING THE SHEET MATERIAL IN A REGISTERED CONDITION INTO THE DEFORMING NIP, AND FEEDING MEMBERS ARE PROVIDED ON THE DIE PLATES TO ASSIST IN ADVANCING THE SHEET MATERIAL THROUGH THE NIP AND MAINTAIN THE SHEETS IN THEIR REGISTERED CONDITION

April 6, SARKA Re.

I SHEET MATERIAL FORMING APPARATUS Q Original Filed Dec. 6. 1965 4Sheets-Sheet 1 we w INVENTOR.

ALBERT J. SARKA BY ATTORNEYS April 6; 1971 A. J. sA RKA SHEET MATERIALFORMING APPARATUS Original Filed Dec. s, 1965 4 Sheets-Sheet a INVENTOR.

ALBERT J. SARKA BY ATTORNEYS April 6, 1971 A. J. SARKA 27,113

' SHEET MATERIAL FORMING APPARATUS Original Filed Dec. 6, 1965 4Sheets-Sheet s INVENTOR.

ALBERT J. SA R KA BY ATTORN EYS April 6, 1971 SARKA Re. 27,113

SHEET MATERIAL FORMING APPARATUS Original Filed Dec. 6, 19654Sheets-Sheet 4 FIG.9

INVENTOR.

ALBERT J. SARKA BY WWW/MW ATTORNEYS United States Patent Ofitice Re.27,113 Reissued Apr. 6, 1971 27,113 SHEET MATERIAL FORMING APPARATUSAlbert J. Sarka, Fairview Park, Ohio, assignor to Harris- IntertypeCorporation, Cleveland, Ohio Original No. 3,383,991, dated May 21, 1968,Ser. No.

512,576, Dec. 6, 1965. Application for reissue Feb.

19, 1970, Ser. No. 12,873

Int. Cl. B31b 1/14 U.S. Cl. 9358.2 25 Claims Matter enclosed in heavybrackets II] appears in the original patent but forms no part of thisreissue specification; matter printed in italics indicates the additionsmade by reissue.

ABSTRACT OF THE DISCLOSURE A pair of rotary cylinders define a materialforming nip. The rotary cylinders have complementary die plates mountedthereon. The die plates have projecting mean's thereon which cooperateto simultaneously cut and crease sheet material as it is advancedtherebetween. Means is provided for conveying and introducing the sheetmaterial in a registered condition into the deforming nip, and feedingmembers are provided on the die plates to assist in advancing the sheetmaterial through the nip and maintain the sheets in their registeredconditionv The present invention relates to a method and apparatus forforming material and, in particular, to a cutting and creasing methodand apparatus wherein cylinders carrying cooperating material formingmembers rotate to effect cutting and creasing of material advancedthrough the nip defined by the cylinders.

The principal object of the present invention is the provision of a newand improved high-speed method and apparatus for cutting and creasingsheet material and wherein a sheet to be cut and creased is registeredand advanced to rotating cylinders carrying a plurality of projectingmembers which rotate with the cylinders and engage the material andeffect the cutting and creasing of the sheet material and feeding of thesheet material through the nip defined by the cylinders whilemaintaining the sheet properly registered.

A further object of the present invention is the provision of a new andimproved method and apparatus for cutting and creasing sheet materialand wherein a sheet to be cut is registered and advanced to rotatingcylinders supporting die plates carrying a plurality of projectingmembers which rotate with the cylinders and engage the material andeffect the forming of the material and Wherein gripper means on one ofthe cylinders engages the leading edge of the sheet material andadvances the sheet into the nip of the cylinders and releases theleading edge of the sheet immediately after the leading edge isintroduced into the cylinder nip so that the sheet is then advanced bythe projecting means on the die plates.

A still further object of the present invention is the provision of anew and improved cutting and creasing apparatus for cutting and creasingsheet material and wherein a sheet to be cut or creased is registeredand advanced to rotating cylinders carrying a plurality of projectingmembers which rotate with the cylinders and engage the material toeffect forming of the material, and wherein one of the cylinderssupports gripper means for engaging the registered sheet at the leadingend thereof and for carrying the leading end of the sheet into the nipdefined by the cylinders and wherein the gripper means is releasedimmediately after the delivery of the leading end of the sheet materialinto the nip so that the material may be delivered from the nip in apath other than the path of movement of the grippers.

Still a further object of the present invention is the provision of anew and improved high-speed apparatus for cutting and creasing sheetmaterial and wherein a sheet having a printed image thereon and which isto be cut is registered and advanced to rotating cylinders carrying aplurality of projecting members which rotate with the cylinders andengage the material to effect cutting thereof, and wherein mechanicallyactuated grippers located in a gap in one of the cylinders and rotatabletherewith grip the sheet at the leading edge of the sheet and advancethe leading edge of the sheet through the nip defined by the cylindersand release the leading edge of the sheet immediately after introducingthe leading edge of the sheet into the cylinder nip.

Another object of the present invention is the provision of cuttingand/or creasing dies to be mounted on rotating cylinders and which diescomprise flexible plates having projecting elements thereon whichcooperate to cut and crease the material as the cylinders rotate andwherein the dies include projecting feed elements which engage oppositesides of the material to effect feeding of the material upon rotation ofthe plates with the cylinders.

Still another object of the present invention is the pro vision of a newand improved cutting and creasing apparatus for cutting patterns insheet material having a printed image thereon and wherein the pattern iscut into the sheet material by cooperating die plates carried by therotating cylinders, and the sheet is registered prior to delivery to thecylinders so as to properly locate the printed image on the sheet, andwherein the cylinders are relatively adjustable and the dies are alsoadjustable on the cylinders so as to provide for proper cutting of thesheet material and registry of the pattern to be cut in the sheetmaterial with the printed image on the sheet material.

Further objects and advantages of the present invention will be apparentto those skilled in the art to which it relates from the followingdetailed description of a preferred embodiment thereof made withreference to the accompanying drawings and in which:

FIG. 1 is a schematic side elevational view of a cutting and creasingapparatus embodying the present invention;

FIG. 2 is a schematic view illustrating sheet material in one operativeposition in the apparatus of FIG. 1;

FIGS. 3 and 4 are fragmentary perspective views illustrating differentportions of the apparatus of FIG. 1;

FIGS. 5 and 6 are fragmentary schematic sectional views of a portion ofthe apparatus of FIG. 1 illustrating operative positions thereof;

FIG. 7 is a fragmentary sectional view illustrating a further portion ofthe apparatus of FIG. 1;

FIG. 8 is a schematic view illustrating parts of the apparatus of FIG.1; and

FIG. 9 is a view of the apparatus of FIG. 1 partially in elevation andpartially in section.

The present invention provides animproved method and apparatus forforming material and, particularly, provides an improved method andapparatus for cutting and/or creasing material wherein cylinderscarrying c0- operating material forming portions rotate to effect thecutting and/ or creasing of the material advanced through the nipdefined by the cylinders. Certain features of the present invention areapplicable to methods and apparatuses for cutting and/or creasingmaterial in either web or sheet form. Moreover, the present inventionfinds particular utility in the cutting and creasing of cardboard sheetshaving an image printed thereon to form a box lank therefrom, with theprinted image forming a label ackground, or other marking on the box.

Accordingly, as representing the preferred embodiment E the presentinvention, FIG. 1 illustrates a cutting and :easing apparatus forcutting and creasing cardboard ieets having a printed image thereon toform box blanks lerefrom. The cutting and creasing apparatus 10 isoperble to cut and/or crease material and includes a pair f cylinders11, 12 which rotate in close proximity and efine a nip therebetween. Asmaterial is advanced through 1e nip defined by the cylinders 11, 12, itis cut and/or teased.

Cutting and/or creasing of the material is performed y sheet-formingelements carried by the cylinders 11, 12. he sheet-forming elements inthe preferred embodiment re formed integrally with and project fromflexible plates r dies 14, carried by the cylinders 11, 12,respectively. he plate 14, as shown in FIG. 3, carries a plurality ofrojecting forming elements, some of which, designated 5, constitutecutting elements, while others, designated 7, constitute creasingelements. The plate 15 carried by re cylinder 12 and shown in FIG. 4also includes a vurality of cutting elements 18 and creasing elements 19hich cooperate with the cutting and creasing elements 1 the plate v14 toeffect cutting and creasing, respectively, 5 the material advancedthrough the nip of the cylinders. he plates 14, 15 are flexible metalplates which may be adily curved to the circumference of the cylinders11, 12 id are secured thereon in a manner to be described :reinbelow.The plates have sufiicient flexibility so that hen removed from thecylinders 11, 12, they return to fiat condition.

The plates 14, 15 have the cutting and creasing eleents thereon formedintegrally therewith and the cutrg and creasing elements are in the formof projecting embers or lands which extend from a base portion of eplates 14, 15, respectively, and cooperate to effect the ltting andcreasing operation. The creasing and cutting ements are formed byetching the plates so that the easing and cutting elements project fromthe base porm thereof in a predetermined pattern. The pattern is ctatedby the particular box blank being formed and ill vary from job to job.The cutting lands 16, 18 cooperate upon rotation to Eect cutting of thesheet material advanced between e cylinders 11, 12. The lands 16, 18engage the sheet aterial, as best shown in FIG. 6, in a slightlyoverlapng relationship with each other, and extend through the eetmaterial a substantial distance, but do not touch, 1d effect a so-calledruptured cutting of the material. 1e creasing elements 17, 19 cooperateto effect a creasg of the material as it is advanced through the nip ofe cylinders 11, 12. The creasing elements comprise operating male andfemale members which cooperate crease the material advanced through thenip of the linders. The male members 19 are shown in the drawgs ascarried by the plate 15, while the female members e shown as carried bythe plate 14. The male members comprise projecting lands which projectfrom the base rtion of the plate 15, as shown in FIG. 4. Each femaleeasing member is shown as being carried by the plate 14 .d constitutes apair of spaced lands 17a, 17b. Sheet aterial advanced through the nip ofthe cylinders 11, 12 creased by the cooperative action of the malecreasing ember 19 with the female creasing members 17a, 17b. i bestshown in FIG. 5, the male creasing member 19 effective to engage thematerial intermediate the female easing members 17a, 17b to effect aforcing of the mate l1 between the female creasing members and thereby'ect a creasing of the sheet material.

The ruptured cutting effected by the cutting lands 16, 18 d the creasingof the sheet material as effected by the male and male creasing lands,are described in United ates patent to Downie, No. 3,142,233, issued byJuly 28, 64. The above-mentioned patent describes the particu- 4 lardimensioning of these lands for carrying out the purposes of rupturedcutting and creasing, and the particular dimensioning of the lands inthe present structure is the same as that disclosed in the Downiepatent.

In the present embodiment, as noted hereinabove, the cooperating plates14, 15 and, particularly, the sheetforming members carried by the platescooperate to rupture cut sheet material and to crease the sheet materialas it is advanced between the cylinders 11, 12. The sheetformingmembers, in particular, are arranged on the plates so as to cut apattern into the sheet and in the specific embodiment shown, arearranged so as to cut a pattern for a box blank. In the preferredembodiment, the sheets are printed sheets and have a printed imagethereon which is to take a predetermined position on the box, as alabel, etc. Thus, the sheet material which is fed through the nip of thecylinders 11, 12 must be properly registered with the cutting patternsand creasing patterns on the plates 14, 15 so that the cutting of thesheet material takes place at the proper locations with respect to theprinted image on the sheet material.

In order to ensure that the printed image on the sheet material isproperly registered with the pattern of projecting lands on the plates14, 15, the apparatus 10 includes a sheet registering mechanism,generally designated 20, for registering the sheet prior to delivery tothe cylinders 11, 12. The sheet material to be delivered to thecylinders 11, 12 is advanced by a suitable conveyor 22 to a feedboard23. The sheet is registered on the feedboard 23.

A sheet having a sample plurality of printed images A thereon,designated by the dotted lines shown in FIG. 2, is shown in registeredposition so that the images A must be properly located with respect tothe sheet-forming elements on the cylinders 11, 12 when the sheetarrives in the nip of the cylinders. The outline of the image Aillustrated in FIG. 2 is shown in dotted lines 18a which comprise thelines to be cut by the cutting lands 16, 18, while the full lines 18bindicate the location where the sheet is to be creased by the creasingmembers 17, 19. The material of the sheet outside the images A becomeswaste. It should be noted that the images A at the leading edge of thesheet are spaced somewhat from the leading edge B of the sheet, therebyproviding an area D of the sheet which will eventually become waste.

The sheet is registered by front stops 25, shown schematically in FIG.2, which move into the path of the leading edge B of the sheet and stopthe sheet, thereby registering the leading edge of the sheet. A suitableside edge registry of the sheet is also effected by means of a pair ofro lers 26 which move into engagement with the sheet and move the sheetlaterally of the feedboard in the direction of the arrow shown in FIG. 2so that the side edge C engages side lays or stops 27. The sheet is thusregistered against the side lays for side registry purposes and is frontregistered against the front stops 25. The front stops 25 comprise theouter tips of arm members 30 which are supported for pivotal movementwith a shaft 31. The shaft 31 when pivoted moves the stops 25 out of thepath of movement of the sheet and a roller 35 moves into engagement withthe underside of the sheet and presses the sheet against a roller 36which cooperates therewith to effect feeding of the sheet toward anadvancing cylinder 37.

The advancing cylinder 37 carries a gripper means 38 which engages thesheet and carries it with the cylinder 37. The gripper means 38 may beof any construction but preferably and as illustrated comprises aplurality of gripper fingers movable relative to a gripper post andwhich engage the sheet in the area D at the leading end thereof. Thegripper means 38, once it has gripped the sheet, maintains the registryof the sheet and carries the sheet, upon rotation of the cylinder 37, toa sheet-advancing transfer cylinder 40. The transfer cylinder 40 alsocarries a gripper means 41 in a gap 42 in the cylinder. The grippermeans 41 cooperates with the gripper means 38 upon rotation thereof totake the sheet from the gripper means 38 and yet maintain the registrythereof.

The gripper means 41, after it takes the sheet, rotates with thecylinder 40 and carries the leading edge of the sheet which is stillmaintained in registration toward the cylinder 12. The cylinder 12carries means thereon for engaging the leading edge of the sheet andtaking the sheet from the gripper means 41 carried by the cylinder 40 sothat the sheet then travels with the cylinder 12. In the preferredembodiment, as shown in the drawings, the means for engaging andgripping the sheet at the leading edge thereof comprises a gripper means50 which engages and takes the sheet from the gripper means 41 on thecylinder 40 and carries the leading edge of the sheet therewith uponrotation of the cylinder 12..

The gripper means 50 comprises a plurality of gripper fingers 50a whichare supported in a gap 51 in the cylinder 12 and are movable to agripping position to grip the sheet, and are movable to a releaseposition to release the sheet. The gripper fingers 50a engage the sheetin the area B forward of the printed images A thereon are moved betweentheir gripping and release positions by cam means in a manner wellknown. As should be readily apparent from FIG. 1, the gripper means 50takes the sheet at the point where the cylinders 40 and 12 rotate inclosest proximity and then introduces the leading edge of the sheetthrough the nip defined by the cylinders 11, 12. When the gripper meanshas advanced the leading edge of the sheet into the nip defined by thecylinders 11, 12, the gripper means 50 is released. This release occurswhen the gripper means is approximately at location X as designated inFIG. 1. When the gripper means 50 releases the leading edge of thesheet, the sheet is thus no longer under the control of the grippermeans and the gripper means proceeds to a position to engage the nextsheet delivered to the cylinder to carry the next sheet into the nipdefined by the cylinders 11, 12.

The sheet, after it is released by the gripper means 50, is advancedthrough the nip of the cylinders 11, 12 by cooperative projecting meanson the plates 14, 15. The plates 14, 15 include, as noted above, aplurality of projecting members which deform the sheet material. Thesemembers, it has been discovered, may be effective to feed the sheetmaterial through the nip without destroying the registration thereof.Whether or not feeding of the sheet in this manner occurs depends uponthe force applied thereto by the projecting members. The creasingelements on the plates 14, 15 do provide a substantial feed force, whilea lesser but effective feed force is applied by the cutting elements.Moreover, the feed force must be applied rather uniformly across thewidth of the material to ensure proper feeding without destroying theregistry of the sheet. Thus, it should be obvious that the particularpattern on the plates 14, 15 will have an effect on the feeding of thesheet by the plates 14, 15.

In the present embodiment, the plates 14, 15 include projecting members70 located on the plates in those areas where the forming members whichform the material would be ineffective to feed the sheet materialthrough the nip and maintain registry thereof. The projecting members 70are of any suitable construction and preferably are made of a rubbermaterial, such as sponge rubber, and are secured to the plates in anypreferred manner, such as by adhesive, so as to engage the material witha slight pressure on the opposite side thereof and feed the materialthrough the nip of the cylinders 11, 12. The projecting members 70engage the material over a wide area and ensure and maintain theregistration of the sheet while feeding the sheet through the cylinders.The projecting members 70 are positioned at spaced locations on theplates 14, 15 so as to provide the necessary driving force along withthe sheet deforming members and generally are located where there arelittle or no creasing members to effect the feed. These particularmembers, however, rather than being of a rubber-like material, could bein the form of milled lands integral with the base portion of the plates14, 1'5 and of substantial width and extent so as not to interfere withthe proper operation of the cutting and creasing elements on the dies14, 15, but yet provide for the feeding of the sheet through the nip.

It should be apparent, of course, that the leading edge of the sheet, asit leaves the nip of the cylinders 11, 12, does not tend to move withthe cylinder 12 or the gripper means 50, but rather tends to move underthe influence of the feeding elements carried by the plates 14, 15. Theleading edge of the sheet, as it leaves the nip defined by the cylinders11, 12, is engaged and supported by a suitable conveyor arrangement,designated 80. The conveyor arrangement includes a suitable lower tapeconveyor 81 l which engages and supports the leading edge of the sheetfor movement in a straight line substantially tangential to thecylinders at the nip thereof. An upper tape conveyor 82 cooperates withthe lower tape conveyor 80 to guide the sheets from the cylinders 11,12.

From the above description, it should be readily apparent that theconstruction of the apparatus 10 is such that registry of the sheet ismaintained so that the sheet may be cut in the desired pattern in thedesired locations on the sheet material with respect to the printedimage thereon, and the registry of the sheet is maintained while thesheet is being delivered to the cylinders 11, 12 for cutting thereof.Also, it should be apparent that, once the leading edge of the sheet hasbeen advanced into the nip of the cylinders 11, 12, it is released byrelease of the grippers 50 and the sheet is then maintained in registryand fed through the nip of the cylinders 11, 12 due to the projectingmeans on the plates carried by the cylinders, thus ensuring that properregistry of the sheet is maintained at all times and that the sheet isproperly out to provide the desired pattern and location of the patternin relation to the'printed image on the sheet material.

The apparatus shown in FIG. 10 is, of course, adjustable so as to cutdifferent patterns on different size sheets and on sheets of differentthicknesses. This necessitates, of course, adjustment and changes in theapparatus and, particularly, in the location of the sheet deformingelements carried by the cylinders 11, 12. For the cutting of differentpatterns on different sheet material, different flexible plates can beconstructed and mounted on the cylinders 11, 12. The plate 14 is securedon the cylinder.

11 by clamps located in a gap 82 in the cylinder 11, while the plate 15is secured on the cylinder 12 by clamps located in the gap 51 therein.These clamps may be of any suitable construction but preferably are asshown and described in copending application, Ser. No. 488,349, filedSept. 20, 1965.

The plate clamps for holding the plates 14, 15 on the cylinders 11, 12,respectively, are identical in construction and only the plate clampsfor holding the plate 15 on the cylinder 12 will be described in detail.It should be understood, of course, that the specific construction ofthe plate clamps carried by the cylinder 12 is the same as that carriedby the cylinder 11 and similar parts of these plate clamps are given thesame reference numbers.

The plate clamps for the holding plate 15 on the cylinder 12 are, asnoted hereinabove, located in an axially extending gap 51 in thecylinder 12. The plate 15 extends around the cylinder and its oppositeends terminate adjacent the opposite sides of the gap 51. A front edgeplate clamp unit is located at one edge of the gap 51 to clamp theforward edge of the plate 15 to the cylinder, while a trailing edgeplate clamp unit 91 is located at the opposite edge of the gap 51 toclamp the trailing edge of the plate 15 to the cylinder 12.

The plate clamp unit 90 comprises a plurality of pairs of relativelymovable plate clamping jaws 92 and 93 which are operable to clamp theleading. edge of the plate 15 therebetween. Each jaw 93 is movablerelative toits associated jaw 92 between open and closed positions toclamp the leading edge of plate 15 therebetween. Each .w 93 is biased toan open position away from the jaw Z. by compression springs, not shown,and may be moved P a closed or clamping position by rotation of a rod 1-which when rotated moves the jaw 93 between its pen and closedpositions. Suitable means are associated ith the forward plate clamp 90so as to provide for lovement of the unit 90 circumferentially of thecylinder as to cause the plate to tightly engage the cylinder Z. Thismeans is in the form of jackscrews 95, only he of which is shown in thedrawings, and which are lreadedly engaged in a threaded opening in thejaw 3 and project through an aligned opening in the jaw 92. hejackscrews 95 each have a forward end or tip which held in abuttingengagement with the bottom wall E a cutout portion of the cylinder 12.By turning the :rews 95, the forward ends thereof bear against the cututportion of the cylinder and cause the plate clamp nit 90 to move awayfrom the adjacent side of the gap )r adjustment of the plate 15 on thecylinder 12.

The rear plate clamp unit 91 which clamps the trailing de of the plate15 to the cylinder 12 comprises a pair E relatively movable jaws orplate clamping members and 126. The jaw 126 is rockable between an openasition and a closed position relative to the jaw 125. The vw 126 ismoved between its open and closed positions pon rotation of a rod 127.The jaw 126 is carried by le jaw 125 and the jaw 125, in turn, isslidably supported r movement in the gap 51 relative to the cylinder 12)r purposes of properly positioning and locating the late 15 on thecylinder 12 in a snug tight manner.

When it is desired to locate the die plate 15 on the llinder 21, theforward plate clamp unit 90 is moved to open position and the leadingedge of the plate 15 positioned between the jaws 92, 93. The jaws havepenings therein designated 130 and 131, see FIG. 8, and 1e plate 15 hascorresponding openings which are adapted be aligned with the openings130, 131 in the jaw 93 E the plate clamp unit 90. Registration pins areinserted .to the aligned openings in order to properly locate the late15 relative to the plate clamp unit 90 on the cylinder I. The leadingedge of the plate is then clamped into )sition and the gauge pins whichare located into the )enings 130, 131 may be removed therefrom. Afterthe ading edge of the plate is clamped, the cylinder 12 is gged torotate under pressure to a position until only 1e trailing edge of theplate 15 remains free. The trail- ,g edge of the plate is then insertedbetween the jaws I5, 126 of the plate clamping unit 91. The plateclamping nit 91 is also provided with an opening 132 in the :ntral jawthereof and a gauge pin is adapted to be lserted through the opening 132and into an aligned pening in the plate 15. The rear plate clamp unit 91then moved to its closed position to secure the plate 5 on the cylinder12.

In view of the particular construction of the plates 1, 15, it isdesirable to provide for adjustment of the ates 14, 15 on the cylinders11, 12 so that the plates I, 15 properly cooperate to effect the cuttingand creasg of the sheet material. If the plates 14, 15 are not roperlyadjusted, the cooperating projecting lands for ltting and creasing ofthe material will not be effective id as a result, the plates will notoperate as desired. 0 provide for adjustment of the plates, the plateclamp nits 90, 91 are adjustable axially of the cylinder 12. Anyljustment mechanism may be provided, and a suitable ljustment mechanismis shown schematically in FIG. 8. he adjustment of the plate clamp unit'90, as shown hematically in FIG. 8, is accomplished by means of a iirof adjusting screws 140, 141 which are located at posite sides of thecylinder 12 and are threaded into ame portions 142, 143, respectively.The adjusting news 140, 141 bear against the opposite portions of the.ate clamp units 90 and may be threaded into and out E the frameportions 142, 143 to effect axial movement thereof. The adjustment ofthe trailing edge plate clamp unit 91 is provided in a similar manner bya pair of adjusting screws 145, 146 which are threaded into frameportions 147, 148, respectively. The adjusting screws 145,

v 146 bear against opposite portions of the trailing plate clamp unitand may be threaded into and out of the frame portions 147, 148 toeffect axial movement of the plate clamp unit 91.

From the above, it should be readily apparent that the plates 14, 15 maybe adjusted somewhat on the cylinders 11, 12, respectively, by movementof the plate clamps. However, the adjustment of the plate clamp units isrelatively slight and may be effected for providing the necessaryalignment between the plates for proper cooperation with the cuttingelements. However, where adjustment to a greater extent is necessary toeffect proper alignment of the pattern of material forming members withthe images A, as well as proper cutting and creasing, the apparatus maybe adjusted by bodily moving one of the cylinders 11 or 12 with respectto the other. By way of example, the drawings illustrate that thecylinder 11 is adjustable relative to the cylinder 12. The cylinder 11may be moved toward and away from the cylinder 12 in order to adjust thegap between the cylinders and adjust the nip therebetween. The cylinder11 may also be moved axially relative to the cylinder 13 and therebyadjust the axial position of the plates thereon. The cylinder 11 mayalso be rotated relative to the cylinder 12 for adjustment purposes toproperly adjust the circumferential location of the material formingelements on the cylinder 11 relative to the material forming elements onthe cylinder 12. The particular construction and particular mounting ofthe cylinder 11 for such adjustment purposes is shown in FIG. 9 and issimilar to the construction shown in copending application Ser. No.266,308, filed Mar. 19, 1963, now abandoned.

Referring now to FIG. 9, which illustrates the cylinders 11, 12 withoutplates 14, 15, respectively, mounted thereon, the cylinder 12 is shownas secured to a shaft 150. The opposite ends of the shaft 150 arerotatably supported by suitable bearing assemblies. The cylinder 11 issecured to a shaft 151 which extends parallel to the shaft 150, and theopposite ends of which are rotatably supported by bearing assemblies152, 153. The hearing assemblies 152, 153 are positioned in andsupported by sleeve members 154, 155, respectively, for sliding movementrelative thereto, for a purpose to be described hereinbelow. Thecylinders 11, 12 are rotated in unison by a driving helical gear 156which meshes with a helical gear 157 fixedly mounted on the shaft 150and which, in turn, meshes with a helical gear 158 supported on theshaft 150, but nonrotatable with respect thereto. The gear 158 issplined to shaft 151 and is axially slidable therealong, for a purposeto be described hereinbelow.

As noted above, the cylinder 11 is adjustable relative to the cylinder12. The adjusting mechanism for cylinder 11 includes means 160 formoving the cylinder 11 axially relative to the cylinder 12, means 161for rotating the cylinder 11 relative to the cylinder 12, and means 162for moving the cylinder 11 toward and away from the cylinder 12. Theadjusting means 160 for moving the cylinder 12 axially preferablyincludes a screw 165 extending parallel to shaft 151. The left end ofthe screw 165, as viewed in FIG. 9, extends to the left beyond thebearing assembly 152 and is provided with a head so that a suitabletool, such as a wrench, may be used to rotate the screw. The other endof the screw 165 is provided with an enlargement thereon located in agroove in the sleeve member 154- which slidably supports the bearingassembly 152. The groove permits the enlargement to rotate relative tothe sleeve member 154 but prevents any axial movement of the screws 165relative to the sleeve member 154. The screw 165 extends through and isthreadedly engaged in a threaded passageway in a projecting portion 166of the bearing assembly 152.

It should be apparent from the above that upon rotation of the screw165, the projecting portion 166 is moved along the screw 165 and thebearing assembly 152 moves. The bearing assemblies 152, 153 thus sliderelative to the sleeves 154, 155, respectively, and the cylinder 11 ismoved axially of the cylinder 12. A plurality of screws corresponding toscrew 165 may be utilized, if deemed desirable.

The adjusting mechanism 161 for rotating the cylinder 11 relative to thecylinder 12 to effect the angular adjustment preferably comprises ascrew 170 which extends parallel to shaft 151 and which is moved axiallyto effect the adjustment. The screw 170 threads into a collar 171 whichis fixedly secured to the shaft 151 of the cylinder 11 and projects tothe left outwardly beyond the collar, as the latter is viewed in FIG. 9.The inner end of the screw 170 is secured to the gear 158 which, asafore-mentioned, is slidably mounted on the shaft 151. The screw 170 issecured to gear 158 for rotation relative thereto and is held againstaxial movement relative thereto, and upon rotation, the screw 170 movesaxially relative to the collar 171 and causes the gear 158 to slideaxially along shaft 151 relative to the gear 157. Since the gears 158,157 are helical gears, axial movement of the gear 158 relative to thegear 157 causes the gear 158 to be rotated, and rotation of the gear 158causes rotation of the cylinder 11. This alters the angular relationbetween cylinders 11, 12 and the plates mounted thereon. The gear 157does not rotate relative to gear 158 because driving gear 156 in meshwith gear 157 provides a resistance to such rotation. It should beapparent from the above description that a plurality of screws 170 maybe used to move gear 158, if desirable.

To provide adjustment of the cylinder 11 toward and away from thecylinder 12, the sleeves 154, 155 which support the opposite ends of theshaft 151 for the cylinder 11 are each slidable on a pair of rodelements 180. The rod elements extend generally parallel to a linethrough and perpendicular to the axes of the cylinders 11, 12. The rodelements are fixed relative to cylinder 12 and are shown as having theirends 180a adjacent cylinder 12 welded to the frame. The sleeves 154, 155engage nuts 181 threaded onto the rod elements and are urged to aposition in engagement with the nuts by springs 182 disposed about theupper ends of the rod elements 180. The springs 182 each have one endabutting the adjacent one of the sleeve members 154, 155 and the otherend abutting a stop provided by a washer which bears against arespective nut 183 threaded onto the outer end of the respective rodelement. The cylinder 11 may be moved toward or away from the cylinder12 along a path parallel to the rods 180 by adjusting the nuts 181,which causes movement of the sleeve members 154, 155, respectively,relative to the frame 10, and the force with which the cylinder 11 isheld against the nuts 181 may be adjusting the nuts 183. The teeth ofthe helical gears 157, 158 are constructed so that there is sufiicientplay in the teeth in a radial direction to permit the desired amount ofmovement of the cylinder 11 without breaking the accurate intermeshingengagement of the gears.

From the above description, it should be readily apparent that applicanthas provided a highly improved method and apparatus wherein projectingforming elements carried by rotatable cylinders cooperate to form thematerial and particularly cut and crease the material. The apparatusprovided is particularly adapted to the cutting of material having aprinted image thereon and which is registered prior to delivery to theforming elements. The forming elements are adjustable relative to eachother so as to properly cooperate in order to effect the cutting andcreasing operation at the desired locations relative to the printedimage.

The present invention has been described hereinabove in considerabledetail and it should be apparent that certain modifications, changes,and adaptations may be 10 made therein by those skilled in the art towhich it relates, and it is hereby intended to cover all suchmodifications, changes, and adaptations coming within the scope of theappended claims.

Having described my invention, I claim:

1. An apparatus for forming sheet material comprising a pair of rotarycylinders having complementary flexible die plates mounted thereon, saidcylinders with the die plates thereon defining a sheet deforming niptherebetween, means for feeding sheets from a supply toward said rotarycylinders, a registering mechanism for registering said sheets with saiddie plates, means for conveying and introducing the sheets in registeredcondition into said deforming nip defined by said cylinders, and each ofsaid die plates having projecting means thereon which cooperate tosimultaneously deform and feed the sheets individually through said nipand maintain the sheets in registered condition as they pass throughsaid nip. 7

2. An apparatus for cutting and creasing sheets having a printed imagethereon comprising a pair of rotary cylinders having complementaryflexible die plates mounted thereon, said die plates having a pluralityof projecting members thereon defining a cutting pattern and cooperableto cut a sheet advanced therebetween, said cylinders with the die platesthereon defining a sheet deforming nip therebetween,. means for feedingsheets having a printed image thereon from a supply toward said rotarycylinders, a registering mechanism for registering said sheets with saiddie plates to locate said sheets so that the printed image is alignedwith the cutting pattern of said die plates when the sheets arrive atsaid nip, means for conveying and introducing the sheets in registeredcondition into said deforming nip defined by said cylinders, and each ofsaid die plates having further projecting members thereon whichcooperate to simultaneously deform and feed sheets individually throughsaid nip and maintain the sheets in registered condition and at leastsome of which also deform the sheets as they pass through said nip.

3. An apparatus for cutting and creasing sheet material having a printedimage thereon comprising a pair of rotary cylinders having complementaryflexible die plates mounted thereon, said cylinders with the die platesthereon defining a sheet deforming nip therebetween, means for feedingsheets having a printed image thereon from a supply toward said rotarycylinders, a registering mechanism for registering said sheets with saiddie plates, means for conveying and introducing the sheets in registeredcondition into said deforming nip defined by said cylinders, said dieplates having a plurality of projecting members thereon defining acutting and creasing pattern and certain ones of which cooperate to cutand crease sheets advanced therebetween and feed the sheets individualythrough said nip and maintain the sheets in registered condition as theyare advanced through said nip.

4. An apparatus for cutting and creasing sheets comprising a pair ofrotary cylinders having complementary flexible die plates mountedthereon, said cylinders with the die plates thereon defining a sheetdeforming nip therebetween, means for feeding sheets from a supplytoward said rotary cylinders, a registering mechanism for registeringsaid sheets with said die plates, means for conveying and introducingthe sheets in registered condition into said deforming nip defined bysaid cylinders, and each of said die plates having projecting cuttingmembers cooperable to rupture cut sheets and projecting creasing memberscooperable to crease sheets and feed the sheets individually throughsaid nip and maintain the sheets in registered condition as they areadvanced through said nip.

5. An apparatus for cutting and creasing sheet material as defined inclaim 4 wherein said die plates include further non-sheet deformingprojecting members 1 1 iaving a feeding contact with the sheet over asubstantial width of the sheet.

6. An apparatus for cutting and creasing sheet ma- :erial as defined inclaim 5 wherein said further proecting members on said die platescomprise resilient pads secured to said die plates in areas spaced fromraid projecting sheet deforming members and which engage the sheet overan area to effectively feed the sheet :hrough the nip.

7. An apparatus for cutting and creasing sheet material as defined inclaim 4 wherein said means for con-- leymg and introducing the sheets inregistered condition .nto said deforming nip includes means carried byone at said cylinders and engageable with a sheet at the .eading edgethereof to introduce the sheet into the 11p and operable to release thesheet immediately after he leading edge thereof is advanced into saidnip.

8. An apparatus for cutting and creasing sheet ma- ;erial as defined inclaim 4 wherein said cylinders have ixially extending gaps therein andfurther include plate :lamps located in said gaps for securing said dieplates )u said cylinders, and said means for conveying the :heetscomprises gripper means carried in the gap of )ne cylinder and operableto grip the leading edge of a sheet to advance the leading edge throughsaid nip and then release the leading edge thereof.

9. An apparatus for cutting and creasing sheet maerial as defined inclaim 8 further including means for guiding the leading end of a sheetin a straight path :ubstantially tangential to the circumference of oneof :aid cylinders after release by said grippers and while eing advancedby the projecting means on said die plates.

10. An apparatus for cutting and creasing sheet maerial as defined inclaim 8 further including means for aodily moving said cylinders foradjustment purposes and means associated with said clamping means foradusting said die plates relative to said cylinders.

11. An apparatus for cutting and/or creasing sheets :omprising a pair ofcylinders having surface portions 'otatable adjacent each other, saidsurface portions car- 'ying complementary flexible die plates thereondefinng a sheet deforming nip therebetween, a registering nechanism forregistering sheets prior to their being td'vanced into said nip, meansfor conveying and introlucing the leading edges of the sheets while inregstered condition into said nip including means carried 1y one of thecylinders for engaging the leading edge if each sheet individually andfor delivering the leading :dge through said nip and operable to releasethe leadng edge of the sheet upon being introduced into said tip, andeach of said die plates having a plurality of irojecting members thereonwhich cooperate to simulaneously cut and/or crease the sheet and feedthe sheet hrough said nip and maintain the sheet registered as it Iassesthrough said nip.

12. An apparatus as defined in claim 11 wherein said neans for engagingthe leading edge of the sheet com- Il'iSCS mechanically actuatedgrippers which grip the leadng edge of the sheet.

13. An apparatus as defined in claim 12 further in- :luding means forguiding the leading edge of the sheet n a substantially straight pathaway from said nip after elease by said grippers.

14. An apparatus for cutting and creasing sheet mateial comprising apair of cylinders having surface Porions rotatable adjacent each other,said surface portions larrying complementary flexible die plates thereondeining a sheet deforming nip therebetween and having porions cooperableto effect cutting and creasing of the sheet naterial as it is advancedthrough the nip, a registering mechanism for registering a sheet priorto its being ad- 'anced into said nip, and means for transporting theregstered sheet and introducing the leading edge of the regisstercdsheet into the nip between the cylinders including 12 means carried onone of the cylinders for engaging the leading edge of the sheet and fordelivering the leading edge through said nip and operable to release theleading edge of the sheet upon its being introduced into said mp.

15. An apparatus for cutting and creasing sheet material comprising apair of cylinders having surface portions rotatable adjacent each other,said surface portions carrying complementaryfiexible die plates thereondefining a sheet deforming nip therebetween, each of said die plateshaving a plurality of projecting members, certain ones of whichcooperate to effect cutting and creasing of the sheet material as it isadvanced through the nip, a registering mechanism for registering thesheets prior to their being advanced into said nip, and means fortransporting the registered sheets and introducing the leading edges ofthe registered sheets into the nip between the cylinders includinggripper means carried on one of the cylinders for gripping the sheet atthe leading edge thereof and for delivering the leading edge throughsaid nip and operable to release the leading edge of the sheet uponbeing introduced into said nip.

16. An apparatus as defined in claim 15 wherein said gripper meansincludes portions engageable with the opposite sides of the sheet at theleading end thereof and in advance of the portion of the sheet to becut.

17. An apparatus for cutting and/or creasing material comprising a firstdie member having first and second projecting members thereon, a seconddie member having third and fourth projecting members thereon, saidfirst and third projecting members comprising sheet severing elements inthe form of narrow lands standing above the surface of the main body ofthe plate in shallow relief, said second and fourth forming memberscomprising sheet creasing elements in the form of narrow lands standingabove the surface of the main body of the plate, said sheet severingelements being disposed on the respective plates so that a minor portionof a sheet severing element on one of said plates overlies a minorportion of a coacting sheet severing element on the other of said platesand said creasing elements being disposed so that certain of saidcreasing elements on one plate are located intermediate the creasingelements on the other plate when said elements operate to out and/ orcrease respectively, and each of said dies including further projectingfeed members standing above the surface of the main body of the plateand adapted to engage material advanced between the dies to effectfeeding thereof.

'18. An apparatus as defined in claim 17 wherein said feed memberscomprise resilient pads secured onto said dies in spaced relation tosaid projecting members.

19. An apparatus for cutting and/or creasing sheets comprising a pair ofrotary cylinders having complementary flexible die plates thereondefining a sheet deforming nip therebetween and cooperable to effectcutting and/or creasing of the sheets advanced therebetween, means forfeeding sheet-s toward said rotary cylinders, means for registering saidsheets prior to entering said nip, means for conveying and introducingsaid sheets in registered condition individually into said nip, and saiddie plates including projecting feed elements for engaging the oppositesides of said sheets to effect feeding thereof through said nip.

20. An apparatus as defined in claim 19 wherein said die plates includefurther projecting elements for deforming the material and saidprojecting feed elements are spaced from said further projectingelements.

'21. A method of cutting and creasing sheet material comprising thesteps of advancing sheet material toward a pair of rotating cylindersdefining a cutting nip and carrying flexible die plates halvingprojecting members thereon, registering said sheet material prior to itsentering said nip, engaging the leading edge of the sheet and conveyingthe registered sheet material into said nip defined by said cylinders,releasing the sheet after the leading edge thereof 13 is advanced intosaid nip, engaging the opposite sides of said sheet with said projectingmembers carried by said die plates, and advancing the material throughsaid nip by the engagement thereof by said projecting members.

22. A method of cutting and creasing a sheet comprising the steps ofadvancing a sheet from a supply toward a pair of cylinders carryingcomplementary flexible die plates having a plurality of projectingmembers which cooperate to effect cutting and creasing of the sheetmaterial, registering a sheet prior to its entering said nip, engagingthe leading edge of a registered sheet and transporting the leading edgeof the registered sheet while maintaining registry thereof into the nipbetween the cylinders, releasing the leadging edge of the sheet after ithas been introduced into the nip, cutting and creasing said sheet byengaging the opposite sides of the sheet with said projecting members,engaging opposite sides of said sheet with feed projections on saiddies, and advancing the sheet through the nip by the engagement thereofby the feed projections.

23. A method of cutting and creasing a sheet as defined in claim 22wherein the sheet has a printed image thereon and wherein said sheet isengaged forwardly of the printed image for feeding of the leading edgeof the sheet into the cylinder nip.

24. A method of cutting and creasing a sheet as defined in claim 22further including the step of guiding said sheet in a straight line pathaway from said nip.

25. An apparatus for forming material comprising a first rotatablecylinder, a: first die plate member mounted on said first cylinder, asecond rotatable cylinder mounted adjacent said first rotatable cylinderand defining therewith a material-forming nip, a second die plate membermounted on said second cylinder, each of said first and second die platemembers having a main body and projecting elements in the form of narrowlands standing above the surface of the main body of the respective dieplate members in shallow relief, said projecting elements on said firstand second die plate members cooperating to form material passingthrough said material-forming nip, and each of said die plate membersincluding further projecting feed members standing above the main bodyof the respective die plate members to engage material advanced betweenthe die plate members to eflect feeding thereof.

References Cited The following references, cited by the Examiner, are ofrecord in the patented file of this patent or the original patent.

UNITED STATES PATENTS 419,835 1/1890 Crowell 83-323 25 2,905,067 9/1959Shields 9358.3 3,190,194 6/1965 Kirby et a1. -9358.2

BERNARD STICKNEY, Primary Examiner

